Abstract: The present invention is directed to a method and apparatus for in-line separation of polymer film and non-woven to compensate for the increased width due to stretching in the cross-machine (CD) direction. Due to the stretching in the cross-machine direction, typically by interdigital rolling or tentering, the width of individual webs is increased. To compensate for the increase in width, the apparatus and method of the present invention is employed to provide for in-line separation of the narrow webs. The apparatus of the present invention may allow for simplicity in threading the device, due to the ability to automatically thread individual turning bars by moving the turning bars across the undeflected path of the web.

Abstract: Microporous film products permeable to moisture vapor and which act as barriers to liquid are made by a high speed method. Such microporous products are made at speeds in the order of above 500 fpm to about 1200 fpm. Thermoplastic polymers are melt blended to contain about 35% to about 45% by weight of a linear low density polyethylene, about 3% to about 10% by weight of a low density polyethylene; about 40% to about 55% by weight calcium carbonate filler particles, and about 2% to about 6% by weight of a triblock polymer of styrene.

Abstract: An apparatus for lamination of a non-woven fibrous sheet and an extruded polymer sheet including a web slitter to divide the fibrous sheet into a plurality of webs, a plurality of folding means to fold each web, a plurality of separated turning bars to turn each folded web such that the webs are separated, and an extrusion laminator for laminating the polymer sheet to the separated webs to provide a laminate having a portion of the polymer sheet between the separated webs.

Abstract: A cloth-like microporous laminate of a nonwoven fibrous web and thermoplastic film is made by lamination of a microporous-formable film composition and a nonwoven fibrous web followed by incremental stretching to form the cloth-like microporous laminate. The cloth-like microporous laminate has air and moisture vapor permeabilities, but acts as a barrier to the passage of liquids. The cloth-like laminates are especially useful in fabricating garments in order to provide the breathable qualities of air and moisture vapor transmission with liquid-barrier properties. Such garments include baby diapers, baby training pants, catamenial pads and garments, and the like where moisture vapor and air transmission properties, as well as fluid barrier properties, are needed.

Abstract: An elastic laminated sheet of an incrementally stretched nonwoven fibrous web and elastomeric film and method of making are disclosed. The elastic laminates are especially useful in diapers, surgical gowns, sheets, dressings, hygienic products and the like.

Abstract: A totally biodegradable and/or compostable soft cloth-like composite of totally biodegradable and/or compostable film and totally biodegradable and/or compostable nonwoven and method of manufacture. A totally biodegradable and/or compostable nonwoven fibrous web and a totally biodegradable and/or compostable film are laminated. The laminate is incrementally stretched to produce a totally biodegradable and/or compostable laminate that is softer than that produced when the biodegradable and/or compostable nonwoven web is bonded to the biodegradable and/or compostable film. The soft cloth-like features of the invention are desired in a number of applications including diapers, pants, surgical gowns, sheets, dressings, hygienic products, and the like.

Abstract: Clothing garments and other articles include an elastic laminated sheet having the properties of stretchability and recoverability. The elastic laminated sheet is formed from a nonwoven fibrous web and an elastomeric film laminated to at least one entire web surface. The laminate is incrementally stretched along lines substantially uniformly across its length and width and throughout its depth to form a stretchable and recoverable composite. The elastic laminated sheet is uniquely suited for use in athletic and active wear garments. The composite is also useful for single use or throw away clothing articles such as medical or surgical garments, throw away bathing suits, underpants, undershirts, and garments used in the handling of hazardous or waste materials.

Abstract: Clothing garments and other articles include an elastic laminated sheet having the properties of stretchability and recoverability. The elastic laminated sheet is formed from a nonwoven fibrous web and an elastomeric film laminated to at least one entire web surface. The laminate is incrementally stretched along lines substantially uniformly across its length and width and throughout its depth to form a stretchable and recoverable composite. The elastic laminated sheet is uniquely suited for use in athletic and active wear garments. The composite is also useful for single use or throw away clothing articles such as medical or surgical garments, throw away bathing suits, underpants, undershirts, and garments used in the handling of hazardous or waste materials.

Abstract: An elastic laminated sheet of an incrementally stretched nonwoven fibrous web and elastomeric film and method of making are disclosed. The elastic laminates are especially useful in diapers, surgical gowns, sheets, dressings, hygienic products and the like.

Abstract: A biodegradable thermoplastic film is disclosed comprising an alkanoyl polymer, a destructured starch and an ethylene copolymer. The film can be stretched providing breathability and enhancing its biodegradability.

Abstract: Extrusion laminates of incrementally stretched nonwoven fibrous webs and thermoplastic films are made. A web of spun bonded fibers is incrementally stretched to provide fiber ends extending outwardly from both web surfaces for bonding with the extruded thermoplastic film and to provide a soft fibrous texture to the laminate.

Abstract: Compostable polymeric sheets of biodegradable or environmentally degradable polymers are included. These composite sheets may be made by extrusion and are compostable in municipal solid waste treatment facilities.The composite film is formed by coextrusion of top and bottom water insoluble thermoplastic films having a water soluble polymer therebetween and stretching the composite along line space substantially uniformally across and through the depth of the composite for weakening the strength of the composite while maintaining its water impermeability.

Abstract: Novel, unstretched synthetic papers being virtually free of mechanically produced microvoids and having a porous surface for writing and printing thereon are disclosed. The unstretched synthetic papers of the instant invention are formed typically by extruding from pellets a film or sheet material formed with a continuous olefin resin matrix containing an effective amount of a particulate filler having pre-existing microvoids inherent thereto, such as a diatamaceous earth. The microvoid particulate filler is dispersed somewhat uniformly yet randomly throughout the continuous olefin resin matrix of the unstretched synthetic papers to provide non-mechanically produced microvoids in communication with the surfaces of the unstretched synthetic papers to render said surfaces porous for imparting writeability and printability thereto.

Abstract: An embossed plastic film is made ultra soft and cloth-like by providing a plurality of post-embossed stretched areas along lines that are spaced uniformly across its width and length. The stretched areas are thinner than the unstretched areas. Films also have unique textures and offer cloth-like or non-woven appearances.

Abstract: An improved barrier cuff for disposable absorbent articles such as a diaper is disclosed. A diaper has a liquid-pervious liner, a liquid-impervious backsheet, and an absorbent core disposed between the liner and backsheet, and elastically contractible leg cuffs. The cuff has a proximal edge and a distal edge and is disposed adjacent margins of the disposable diaper and defines a waste containment pocket with the backsheet and liner frontsheet. The cuff being made of an embossed plastic film having a pattern of stretched and unstretched regions. The plastic film provides ultrasoft cloth-like and quiet material for use as a cuff in comparison to known plastic film or laminates. Leakage prevention and comfort to the user are increased because the body exudates are less capable of leaking out of the absorbent article prior to absorption into the core and the wearing comfort is provided by the ultrasoft cuff.